Combination baffle and filter element system for removing oil from an oil/gas mixture

Abstract

A separator tank for removing oil from a gas/oil mixture includes a lower chamber for collecting the oil removed from the gas/oil mixture, an intermediate chamber overlying the lower chamber and an upper chamber overlying the intermediate chamber. The separator tank has an inlet in fluid communication with the intermediate chamber for introducing the gas/oil mixture into the separator tank at a velocity. The intermediate chamber includes a baffle adapted for changing the velocity of the gas/oil mixture as the mixture travels between the inlet and the upper chamber for causing at least some of the oil to separate from the gas/oil mixture. The upper chamber has a diffusing element for reducing the velocity of the gas/oil mixture and an oil coalescing element for separating at least some of the oil from the gas/oil mixture. The separator tank includes an outlet in fluid communication with the upper chamber for discharging the gas from the separator tank after substantially all of the oil has been removed from the gas/oil mixture.

What is claimed is: 
     
       1. A separator tank for removing oil from a gas/oil mixture comprising: a lower chamber for collecting oil removed from said gas/oil mixture;   an intermediate chamber overlying said lower chamber and an upper chamber overlying said intermediate chamber;   at least one inlet in fluid communication with said intermediate chamber for introducing said gas/oil mixture into said separator tank at a velocity;   said intermediate chamber having a baffle adapted for changing the velocity of said gas/oil mixture as said mixture travels between said inlet and said upper chamber for causing at least some of said oil to separate from said gas/oil mixture;   said upper chamber having a diffusing element for reducing the velocity of said gas/oil mixture and an oil coalescing element for separating at least some of said oil from said gas/oil mixture, wherein said diffusing element includes a first flow element adapted for moving said gas/oil mixture in a substantially vertical direction and a second flow element adapted for moving said gas/oil mixture in a substantially horizontal direction said first flow element comprising a plurality of diffusing tubes having first ends adjacent said intermediate chamber and second ends remote therefrom; and   at least one outlet in fluid communication with said upper chamber for discharging gas from said separator tank after said gas/oil mixture has passed through said upper chamber.   
     
     
       2. The separator tank as claimed in claim 1, further comprising a barrier layer extending between and substantially separating said lower and intermediate chambers for preventing said oil collected in said lower chamber from becoming reentrained in said gas/oil mixture. 
     
     
       3. The separator tank as claimed in claim 2, wherein said barrier layer includes one or more openings extending therethrough for allowing said oil removed from said gas/oil mixture to flow from said intermediate chamber to said lower chamber. 
     
     
       4. The separator tank as claimed in claim 1, wherein said separator tank includes an outer wall surrounding at least portions of said lower, intermediate and upper chambers. 
     
     
       5. The separator tank as claimed in claim 4, wherein said outer wall has a substantially cylindrical shape. 
     
     
       6. The separator tank as claimed in claim 4, further comprising at least one oil scavenge extending through said outer wall and opening into said intermediate chamber, wherein at least some of said oil separated from said gas/oil mixture may be removed from said separator tank through said at least one oil scavenge. 
     
     
       7. The separator tank as claimed in claim 4, further comprising at least one oil scavenge extending through said outer wall and opening into said upper chamber, wherein at least some of said oil separated from said gas/oil mixture may be removed from said separator tank through said at least one scavenge. 
     
     
       8. The separator tank as claimed in claim 4, wherein said baffle within said intermediate chamber includes one or more projections extending from an interior region of said outer wall. 
     
     
       9. The separator tank as claimed in claim 3, said intermediate chamber including one or more conduits in fluid communication with said baffle and extending toward said barrier layer for directing at least some of said oil removed from said gas/oil mixture toward said at least one opening in said barrier layer. 
     
     
       10. The separator tank as claimed in claim 1, wherein said diffusing tubes have varying lengths. 
     
     
       11. The separator tank as claimed in claim 10, wherein said second flow element includes a substantially vertical wall having a plurality of apertures extending therethrough. 
     
     
       12. The separator tank as claimed in claim 11, wherein the lengths of said diffusing tubes increase as the distance between said diffusing tubes and said substantially vertical wall increases. 
     
     
       13. The separator tank as claimed in claim 1, wherein said oil coalescing element at least partially surrounds one or more of said diffusing tubes for removing at least some of said oil from said gas/oil mixture as said gas/oil mixture passes therethrough. 
     
     
       14. The separator tank as claimed in claim 1, wherein said oil coalescing element includes a material selected from the group consisting of knitted mesh, metal wool, synthetic resin wool, metal beads, metal filings and porous ceramic material. 
     
     
       15. The separator tank as claimed in claim 11, wherein said plurality of openings in said substantially vertical wall have a diameter of between approximately 1 and 5 mm. 
     
     
       16. The separator tank as claimed in claim 11, wherein at least some of said plurality of openings at a lower end of said substantially vertical wall are smaller than at least some of said plurality of openings at an upper end thereof. 
     
     
       17. The separator tank as claimed in claim 11, wherein at least a portion of said oil coalescing element is in contact with said substantially vertical wall. 
     
     
       18. The separator tank as claimed in claim 1, further comprising an oil discharge valve in fluid communication with said lower chamber for removing said oil collected therein. 
     
     
       19. The separator tank as claimed in claim 1, wherein said intermediate chamber includes one or more oil scavenges adapted for removing at least some of said oil from said separator tank. 
     
     
       20. The separator tank as claimed in claim 1, wherein said upper chamber includes one or more oil scavenges adapted for removing at least some of said oil from said separator tank. 
     
     
       21. The separator tank as claimed in claim 1, wherein said at least one outlet in fluid communication with said upper chamber includes a baffle for removing additional oil from said gas/oil mixture. 
     
     
       22. The separator as claimed in claim 1, wherein said separator tank has an outside diameter of less than approximately six (6) inches.